Protective pads including tethers and related methods and systems

ABSTRACT

A protective pad system may comprise a vest, at least one right shoulder pad and at least one left shoulder pad. The vest may comprise a back region, a left shoulder region, a right shoulder region, and a chest region. The at least one left shoulder pad may be hinged relative to the left shoulder region of the vest, and at least one left front motion restraint device may be positioned and configured to transfer impact force from the at least one left shoulder pad to the chest region of the vest. Likewise, the at least one right shoulder pad may be hinged relative to the right shoulder region of the vest, and at least one right front motion restraint device may be positioned and configured to transfer impact force from the at least one right shoulder pad to the chest region of the vest.

RELATED APPLICATION

The present application claims priority under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/469,570, filed Mar. 30, 2011 titled “Football Shoulder Pads,” the disclosure of which is incorporated herein by reference in its entirety.

FIELD

Systems and methods of the present disclosure relate to protective pads. More specifically, the present disclosure relates to protective pads including tethers that are configured to protect a wearer during an impact, such as during contact sports.

BACKGROUND

Protective shoulder pads and other sports related protective pads are worn by players in a number of contact sports, such as football, hockey, soccer, cricket, and lacrosse. Because of the physical nature of such sports, it is important for the protective gear to fit the players with the protective padding aligned with the intended areas on the players' bodies. Misaligned protective gear could jeopardize a player's safety. It is also important for the protective gear to fit comfortably. An uncomfortable fit could hinder a player's physical and mental performance.

Specifically, football shoulder pads are meant to protect athletes from injuries to their upper body. The focus of current shoulder pad design, in football for example, is impact dispersion. FIG. 1 illustrates a traditional shoulder pad assembly 20. As illustrated, the shoulder pad assembly 20 includes a flexible vest and a pair of rigid shoulder pads 24 attached to the vest 22. A pair of straps 30, 32 extends from a back portion of the vest 22 and is attached to a front portion of the vest 36. More particularly, a first strap 30 extending from a back right side of the vest is attached to a front right side 38 of the vest, and a second strap 32 extending from a back left side of the vest is attached to a front left side 40 of the vest 22.

The illustrated traditional shoulder pad assembly 20 may include a rigid upper shoulder pad 26 and a rigid lower shoulder pad 28 operatively connected to one another. For example, the upper shoulder pad 26 may be secured to the vest 22 atop the shoulder while the lower shoulder pad 28 is connected to the vest 22 by a strap. The lower shoulder pads may hang somewhat freely above the wearer's biceps, thus providing some protection and some freedom of movement. Additional examples of known traditional protective pads are shown in: U.S. Pat. No. 4,610,034; U.S. Pat. No. 4,985,931; U.S. Pat. No. 7,168,104; and U.S. Pat. No. 7,647,651.

When a player's arms and shoulders are raised when wearing traditional shoulder pads, the vest rises with the shoulders and the shoulder portions of the vest move inward, pinching the player's neck. This may be uncomfortable for the player, and may restrict the player's movement. Accordingly, a player wearing traditional pads may not be able to reach overhead to an extent that could be achieved if the player were not wearing such pads. Additionally, when a player is impacted in the shoulder, the force imparted to the shoulder pad, although somewhat distributed, is still directed to the underlying shoulder area of the player.

In view of the foregoing, it would be desirable for improved protective pad systems and methods.

SUMMARY

In one aspect of the present disclosure, a protective pad system may comprise a vest, at least one right shoulder pad and at least one left shoulder pad.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the vest may comprise a back region, a left shoulder region, a right shoulder region, and a chest region.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the at least one left shoulder pad may be hinged relative to the left shoulder region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, at least one left front motion restraint device may be positioned and configured to transfer impact force from the at least one left shoulder pad to the chest region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the at least one right shoulder pad may be hinged relative to the right shoulder region of the vest

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, at least one right front motion restraint device may be positioned and configured to transfer impact force from the at least one right shoulder pad to the chest region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, at least one left back motion restraint device may be positioned and configured to transfer impact force from the at least one left shoulder pad to the back region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, at least one right back motion restraint device may be positioned and configured to transfer impact force from the at least one right shoulder pad to the back region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the at least one left front motion restraint device may comprise a tether coupling a first side of the at least one left shoulder pad to the chest region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the at least one right front motion restraint device may comprise a tether coupling a first side of the at least one right shoulder pad to the chest region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the at least one left back motion restraint device may comprise a tether coupling a second side of the at least one left shoulder pad to the back region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the at least one right back motion restraint device may comprise a tether coupling a second side of the at least one right shoulder pad to the back region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, each tether may have an adjustable free length.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, each tether may comprise hook-and-loop fastener features.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, each tether may have a fixed free length.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, each tether may be relatively rigid.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, each tether may be somewhat elastic.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, each tether may comprise webbing.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, tether may comprise a textile having a generally triangular shape.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, each tether may have a free length that is between about 30% and about 40% of the length of the radial distance from the respective tether to an axis of rotation of the respective shoulder pad relative to the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, each tether may have a free length that is about 35% of the length of the radial distance from the respective tether to an axis of rotation of the respective shoulder pad relative to the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the at least one left shoulder pad may be hinged relative to the left shoulder region of the vest by a top tether having a first end attached near a top of the at least one left shoulder pad and a second end attached to the left shoulder region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the at least one right shoulder pad may be hinged relative to the right shoulder region of the vest by a top tether having a first end attached near a top of the at least one right shoulder pad and a second end attached to the right shoulder region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, each top tether may have an adjustable free length.

An additional aspect of the present disclosure is methods of providing shoulder protection

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the methods may comprise providing a vest comprising a back region, a left shoulder region, a right shoulder region, and a chest region.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the methods may comprise providing at least one left shoulder pad hinged relative to the left shoulder region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the methods may comprise providing at least one right shoulder pad hinged relative to the right shoulder region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the methods may comprise transferring impact force from the at least one left shoulder pad to the chest region of the vest upon impact to the at least one left shoulder pad.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the methods may comprise transferring impact force from the at least one right shoulder pad to the chest region of the vest upon impact to the at least one right shoulder pad.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the methods may comprise transferring impact force from the at least one left shoulder pad to the back region of the vest upon impact to the at least one left shoulder pad.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the methods may comprise transferring impact force from the at least one right shoulder pad to the back region of the vest upon impact to the at least one right shoulder pad.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the methods may comprise transferring impact force from each of the at least one right shoulder pad and the at least one left shoulder pad to the chest and back regions with a tether.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the methods may comprise adjusting a free length of each tether to provide a desired range of arm and shoulder motion.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, the methods may comprise adjusting a free length of each tether to be about 35% of the distance between an axis of rotation of the respective shoulder pad relative to the vest.

In some aspects of the present disclosure, protective pad systems may comprise a vest comprising a back region, a left shoulder region, a right shoulder region, and a chest region.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, at least one left shoulder pad may be hinged relative to the left shoulder region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, a first tether may couple a first side of the at least one left shoulder pad to the chest region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, a second tether may couple a second side of the at least one left shoulder pad to the back region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, at least one right shoulder pad may be hinged relative to the right shoulder region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, a third tether may couple a first side of the at least one right shoulder pad to the chest region of the vest.

In an additional aspect of the present disclosure, which may be combined with any other aspect herein, a fourth tether may couple a second side of the at least one right shoulder pad to the back region of the vest.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate various embodiments of the present system and method and are a part of the specification. The illustrated embodiments are merely examples of the present system and method and do not limit the scope thereof.

FIG. 1 is a frontal view of a traditional shoulder pad assembly.

FIG. 2A is a frontal view of a shoulder pad system including side tethers according to an embodiment of the present disclosure.

FIG. 2B is a back view of the shoulder pad system of FIG. 2A.

FIG. 3 is a cross-sectional view of an adjustable top tether arrangement between upper and lower shoulder pads and a vest of a shoulder pad system, such as shown in FIG. 2A.

FIG. 4 is a cross-sectional view of a fixed top tether arrangement between upper and lower shoulder pads and a vest of a shoulder pad system, such as shown in FIG. 2A.

FIG. 5A is a cross-sectional view of a fixed side tether arrangement between a shoulder pad and a vest of a shoulder pad system, such as shown in FIG. 2A, when the shoulder pads are in a fully lowered position.

FIG. 5B is a cross-sectional view of a fixed side tether arrangement between a shoulder pad and a vest of a shoulder pad system, such as shown in FIG. 2A, when the shoulder pads are in a fully raised position.

FIG. 6 is a cross-sectional view of an adjustable side tether arrangement between a shoulder pad and a vest of a shoulder pad system, such as shown in FIG. 2A, when the shoulder pads are in a fully raised position.

FIG. 7A is a frontal view of a shoulder pad system including side tethers comprising textile pieces according to another embodiment of the present disclosure.

FIG. 7B is a back view of the shoulder pad system of FIG. 7A.

FIG. 8 is an exploded perspective view of a corrugated foam cell pad system which may be utilized with a shoulder pad system, such as shown in FIG. 2.

FIGS. 9A-9C are cross-sectional views of corrugated plate of the corrugated foam cell pad system of FIG. 8.

FIG. 10 is a cross-sectional view of the corrugated foam cell pad system of FIG. 8.

Throughout the drawings, identical reference numbers may designate similar, but not necessarily identical, elements.

DETAILED DESCRIPTION

The present specification describes protective pad systems that may comprise a vest, at least one right shoulder pad and at least one left shoulder pad. The vest may comprise a back region, a left shoulder region, a right shoulder region, and a chest region. The at least one left shoulder pad may be hinged relative to the left shoulder region of the vest, and at least one left front motion restraint device may be positioned and configured to transfer impact force from the at least one left shoulder pad to the chest region of the vest. Likewise, the at least one right shoulder pad may be hinged relative to the right shoulder region of the vest, and at least one right front motion restraint device may be positioned and configured to transfer impact force from the at least one right shoulder pad to the chest region of the vest.

In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present devices, systems and methods. It will be apparent, however, to one skilled in the art that the present devices, systems and methods may be practiced without these specific details. Reference in the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearance of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

As mentioned, the present exemplary system and method provide pads to disperse impact energy so that there is a low transfer of the impact energy to the wearer. According to one exemplary embodiment, the present exemplary system may be incorporated into any number of impact absorption members including, but in no way limited to sports related pads, shoes, helmets, industrial protection equipment, combat gear, and the like. For consistency and ease of explanation only, the present protective pad system and configuration will be described in the context of a football pad system. However, it will be readily understood that the present exemplary protective pad configuration may be incorporated into any number of protective pad applications including, but in no way limited to, hockey pads, lacrosse pads, industrial protective clothing, riot gear, and the like.

FIG. 2A is a front view of a shoulder pad system 110, according to one embodiment. As illustrated in FIG. 2A, the shoulder pad system 110 includes a vest 112, a left upper shoulder pad 114 (e.g., an epaulet), a right upper shoulder pad 116, a left lower shoulder pad 118, a right lower shoulder pad 120, and a tether system for coupling the shoulder pads 114, 116, 118, 120 to the vest 112. Additionally, the shoulder pad system 110 includes a fastening system to couple the shoulder pad system 110 to a wearer. While a strap system 122 is illustrated in FIGS. 2A and 2B, it will be understood that any number of pad fastening systems may be used with the present exemplary system and method including, but in no way limited to one or more of a buckle system, a lace system, a snap system, a hook-and-loop (e.g., VELCRO®) system, and the like.

The vest 112 may include a chest region 124, a left shoulder region 126, a right shoulder region 128, and a back region 130. A single vest plate 132 (e.g., a monolithic plate) may extend over the chest region 124, shoulder regions 126, 128 and the back region 130. The vest plate 132 may include a split in the chest region 124 to facilitate access for a wearer into the shoulder pad system 110. The straps 134 of the fastening system may facilitate closure of the split in the chest region 124 of the vest 112. Additionally, the fastening system may couple each side of a back region 130 of the vest 112 to a corresponding side of the chest region 124 of the vest 112. For example, adjustable straps 136 may extend across the sides of the wearer, under the arms, to couple the back region 130 of the vest 112 to the chest region 124 of the vest 112.

FIGS. 2A and 2B show the left shoulder pads 114, 118 in a fully raised position and the right shoulder pads 116, 120 in a fully lowered position to illustrate the function of the shoulder pad system 110. It should be understood, however, that the left shoulder pads 114, 118 and the right shoulder pads 116, 120 may be generally symmetrical about a central plane of the shoulder pad system 110.

The shoulder pads 116, 118, 120, 124 may be attached to the respective shoulder regions 126, 128 of the vest 112 with top tethers 138, 140 of the tether system. In one embodiment, as shown in cross section in FIG. 3, the resting position (i.e., the fully lowered position) of each of the shoulder pads 114, 116, 118, 120, relative to the vest 112, may be adjustable. Each shoulder pad 114, 116, 118, 120 may include a top tether 138, 140 attached near a top portion thereof. For example, a top tether 138, 140 may be attached near the top of each shoulder pad 114, 116, 118, 120 with one or more rivets 142.

The vest 112 may include a first anchor 144 and a second anchor 146 located at each of the left and right shoulder regions 126, 128. As shown in FIG. 3, each anchor 144, 146 may be defined, respectively, between a pair of slots formed in the vest 112. The top tether 138 attached to the lower shoulder pad 118 may be routed around the first anchor 144 to attach the lower shoulder pad 118 to the vest 112. The free length X1 of the top tether 138 (i.e., the length X1 of top tether 138 between the anchor 144 and the attachment point on the shoulder pad 118) may then be adjusted to fit a specific wearer.

Each top tether 138, 140 may be comprised of a strap (e.g., a webbing formed from synthetic fibers) having cooperative hook-and-loop fastener features extending along a surface 148 thereof. Accordingly, a free end 150 of the top tether 138 may be pulled after insertion through the first anchor 144 until a desired free length X1 is achieved. The free end 150 of the top tether 138 may then be pressed against a fixed end 152 of the top tether 138 and the cooperative hook-and-loop fastener features on the top tether 138 may interlock.

Similar to the lower shoulder pad 118, a top tether 140 attached near the top of the upper shoulder pad 114 may be routed through the second anchor 146 of the shoulder region 126 of the vest 112. The top tether 140 may be adjusted to position the upper shoulder pad 114 over a gap 154 between the lower shoulder pad 118 and the vest 112. Then, a free end 156 of the top tether 140 may be pressed against a fixed end 158 of the top tether 140 and the cooperative hook-and-loop fastener features on the top tether 140 may interlock.

In an additional embodiment, as shown in cross section in FIG. 4, the resting position of each of the shoulder pads 114, 116, 118, 120, relative to the vest 112, may be fixed. A first end 160 of a top tether 162 may be attached to the lower shoulder pad 118. A middle portion 164 of the top tether 162 may be attached to the upper shoulder pad 114. A second end 166 of the top tether 162 may be attached to the shoulder region 126 of the vest 112. For example, fasteners, such as one or more of rivets 168, stitching 170, bolts, and the like, may be used to attach the top tether 162 to the lower shoulder pad 118, the upper shoulder pad 114, and the shoulder region 126 of the vest 112.

In addition to top tethers 138, 140, 162, attaching each of the shoulder pads 114, 116, 118, 120 to a respective shoulder region 126, 128 of the vest 112, the tether system may include side tethers 172, 174, 176, 178 attaching shoulder pads 14, 16 to the chest region 124 and the back region 130 of the vest 112.

In the embodiment shown in FIGS. 2A and 2B, the upper shoulder pads 114, 116 may be sized so that sides of the upper shoulder pads 114, 116 extend over the back region 130 and the chest region 124 of the vest 112, respectively. A first side tether 172 may couple a first side of the left upper shoulder pad 114 to the chest region 124 of the vest 112. A second side tether 174 may couple a first side of the right upper shoulder pad 116 to the chest region 124 of the vest 112. A third side tether 176 may couple a second side of the left upper shoulder pad 114 to the back region 130 of the vest 112. Likewise, a fourth side tether 178 may couple a second side of the right upper shoulder pad 116 to the back region 130 of the vest 112.

The free length X2 (i.e., the length X2 of the side tether 172, 174, 176, 178 between the attachment points at the vest 112 and respective shoulder pad 114, 116, 118, 120) and position of each of the side tethers 172, 174, 176, 178 may be selected to allow the shoulder pads 114, 116 to move upward relative to the vest 112, such as when a wearer's arms are raised overhead. Additionally, the free length X2 and position of the side tethers 172, 174, 176, 178 may be selected to prevent the shoulder pads 114, 116 from moving downward, relative to the vest 112, beyond a specific point (e.g., beyond a point wherein injury may occur to a wearer) when subjected to an impact. Accordingly, impact forces imparted on the shoulder pads 114, 116, 118, 120 may be transferred to the vest 112 through the side tethers 172, 174, 176, 178.

In some embodiments, the side tethers 172, 174, 176, 178 may be relatively rigid, and may stretch relatively little (e.g., less than about 10% of its length) under peak design load. In further embodiments, the side tethers 172, 174, 176, 178 may be somewhat elastic and may stretch (e.g., greater than about 10% of its length) under peak design load. By selecting the fiber material of which the webbing is constructed, the shape and dimensions of the webbing, and the woven construction of the webbing, a webbing material may be selected that provides a desired elastic response for a given application and expected impact forces.

The shoulder pads 114, 116, 118, 120 are rotatable about the top tethers 138, 140. The free length X2 of each of the side tethers 172, 174, 176, 178, and the radial distance of each respective side tether 172, 174, 176, 178 from an axis of rotation (e.g., a distance from the top tether 140) may determine the freedom of movement of the shoulder pads 114, 116 when relatively rigid side tethers 172, 174, 176, 178 are utilized. When relatively elastic side tethers 172, 174, 176, 178 are utilized, the expected elongation under load may also be considered when determining an appropriate free length X2 for each of the side tethers 172, 174, 176, 178.

For football shoulder pads, about 40 degrees of rotation of the shoulder pads 114, 116 about the top tethers 140 may be sufficient to provide acceptable mobility of a wearer's arms and shoulders. In view of this, the free length X2 of each side tether 172, 174, 176, 178 may be between about 20% and about 30% of the length of the radial distance D from the side tether to an axis of rotation of the respective shoulder pad 116, 118 relative to the vest 112. For example, the, the free length X2 of a side tether 172, 174, 176, 178 may be about 35% of the length of the radial distance D from the side tether 172, 174, 176, 178 to an axis of rotation of the respective shoulder pad 116, 118 relative to the vest 112.

As shown in a cross-sectional detail view in FIGS. 5A and 5B, each side tether 172, 174, 176, 178 may be coupled to each respective shoulder pad 116, 118 and to the vest 112 as illustrated with regard to the first side tether 172. As illustrated, the first side tether 172 may have a fixed free length X2. A first end 180 of the first side tether 172 may be coupled to the vest 112 with a fastener. An opposing, second end 184 of the first side tether 172 may be coupled to the shoulder pad 114 with a fastener. For example, the fasteners may be one or more of rivets 182, stitching, bolts, and the like.

As shown in FIG. 5A, when the shoulder pad 114 is lowered to the fully lowered position, the side tether 172 will prevent further downward movement of the shoulder pad 114 relative to the vest 112. Accordingly, upon the shoulder pad 114 receiving an impact force, the side tether 172 will transfer impact force to the chest region 124 of the vest 112.

As shown in FIG. 5B, the free length X2 of the side tether 172 is selected to allow the upward movement of the shoulder pad 114 relative to the vest 112, which may facilitate the mobility of the wearer's arm and shoulder.

As shown in a cross-sectional detail view in FIG. 6, each side tether 172, 174, 176, 178 may be coupled to each respective shoulder pad 116, 118 and to the vest 112 as illustrated with regard to the first side tether 172. As illustrated, the first side tether 172 may have an adjustable free length X2. For example, the first side tether 172 may include a hook-and-loop fastener feature on a surface 186 thereof. A first end 180 of the first side tether 172 may be coupled to the vest 112 with one or more fasteners. For example, the fasteners may be one or more of rivets 182, stitching, bolts, and the like.

An opposing, second end 184 of the first side tether 172 may be routed around an anchor 188 of the shoulder pad 114. The second end 184 of the side tether 172 may be pulled after insertion through the anchor 188 until a desired free length X2 is achieved. The second end 184 of the side tether 172 may then be pressed against the first end 180 of the side tether 172 and the cooperative hook-and-loop fastener features may interlock.

In further embodiments, side tethers of a protective pad system 110 may comprise generally triangular pieces of textile 190 attaching the shoulder pads 114, 116, 118, 120 to the vest 112, as shown in FIGS. 7A and 7B. As shown in FIG. 7A, a first side 192 of each generally triangular piece of textile 190 on the front of the pad system 110 may be sewn to the chest region 124 of the vest 112, and a second side 194 may be sewn to a first side of a respective shoulder pad 114, 116. Likewise, as shown in FIG. 7B, a first side 192 of each generally triangular piece of textile 190 on the back of the pad system 110 may be sewn to the back region 130 of the vest 112, and a second side 194 may be sewn to a second side of a respective shoulder pad 114, 116.

The vests and shoulder pads of the embodiments disclosed with reference to FIGS. 2A-7B may additionally include a corrugated foam cell pad system. FIG. 8 is an exploded perspective view of a corrugated foam cell pad system configured to enhance protection and flexibility, while reducing weight, according to one exemplary embodiment. As illustrated, the exemplary foam cell pad system incorporates the idea of a corrugated plate into a dampening encasement. While the present exemplary system may be practiced by associating a corrugated plate with at least one bottom dampening member, such as a foam, the present exemplary system and method will be described, for ease of explanation only, as incorporating foam as the dampening member. However, it will be recognized that any number of dampening materials may be used including, but in no way limited to, a gel, an encased fluid, an aggregate material, and the like. According to one exemplary embodiment, the corrugated foam cell system 200 includes a foam upper 220 and a foam lower member 230 having a corrugated member 210 disposed there between. According to this exemplary embodiment, the foam upper 220 and lower 230 members work in conjunction with the corrugated member 210 to both absorb and disperse energy received during an impact, while providing enhanced mobility and range of motion to the user, when compared to traditional shoulder pad systems. Additionally, as illustrated in FIG. 8, additional foam 240 may be added to either side of the corrugated foam cell system 200 to modify the comfort of the system for the user. Further details of each component of the exemplary corrugated foam cell concept 200 will be provided below.

As noted above, the corrugated member 210 is disposed adjacent to at least one foam member, and, according to one exemplary embodiment, between a foam upper member 220 and a foam lower member 230. According to one exemplary embodiment, the foam upper member 220 and the foam lower member 230 may be formed of similar or disparate foam materials to vary both energy absorption and user feel. As used in the present specification, the term “foam” shall be interpreted as any substance that is formed by a trapping of gas bubbles in a liquid or a solid, and shall include open and closed cell configurations. According to one exemplary embodiment, a polyurethane foam may be used to form the foam upper member 220 and the foam lower member 230. Alternatively, any number of or combinations of foams may be used to form the foam upper member 220 and a foam lower member 230 including, but in no way limited to as quantum foam, polyurethane foam (foam rubber), XPS foam, Polystyrene, phenolic, Syntactic foam, or any other manufactured foam. According to one exemplary embodiment, the foam upper member 220 and the foam lower member 230 are formed out of commercially available SHOCKtec™ Air2Gel Foam for enhanced impact dispersion. The present exemplary systems and methods were initially implemented using polyurethane foam manufactured by Utah Foam Products (Nephi, Utah) having varying densities and stiffness.

According to the present exemplary system and method, the foam upper member 220 and the foam lower member 230 may be formed around the corrugated member 210 via any number of foam forming methods including, but in no way limited to foaming the foam members in place around the corrugated member 210, pressing the foam around the corrugated member, extruding the foam to mate with the corrugated member, adhering the foam around the corrugated member, mechanically fastening the foam to the corrugated member, shaving or otherwise shaping the foam to mate with the corrugated member, or otherwise forming the foam as is known in the art.

Additionally, as noted above, the exemplary corrugated foam cell concept 200 includes a corrugated member 210 formed of a structural material disposed between the foam upper member 220 and the foam lower member 230. According to this exemplary embodiment, the corrugated member 210 may be formed of any number of thermoplastics or other bendable structural materials. While the present exemplary system is described in the context of the plate being formed of polypropylene or polycarbonate, any number of structural materials may be used to form the corrugated plate including, but in no way limited to polypropylene, polycarbonate including Lexan® from SABIC Innovative Plastics, polyamides such as nylon, and the like. According to one embodiment, Lexan® from SABIC Innovative Plastics is used to form the corrugated member 210 due to its fracture resistance and relatively large modulus of elasticity.

According to one exemplary embodiment, the corrugated member 210 is formed to exhibit a sinusoidal cross-sectional shape. As noted above, while the present exemplary system is described as having a corrugated member 210 with a repeating curved pattern that is similar to the curve of a sine function having crests and troughs. According to the present exemplary system and method, the corrugated member 210 the corrugations of the corrugated member 210 may assume any number of shape profiles to form the alternating grooves and ridges including, but in no way limited to, curves, triangles, substantially squared corners, stepped wave forms, and the like.

FIG. 9A is a frontal cross-sectional view of a corrugated member 210, according to one exemplary embodiment. According to the exemplary embodiment illustrated in FIG. 9A, the cross-sectional view of the corrugated member 210 assumes a consistent and repeating sinusoidal waveform. As illustrated, the cross-sectional member includes a number of measurable features that may be modified to vary the stiffness of the corrugated member 210 in the direction transverse to the ridges and to modify the impact strength, energy dispersion, and durability of the corrugated member or plate. As shown, the wave profile 300 may be modified according to peak to peak wavelength 310 or frequency, material thickness 320, and wave height 330 or amplitude. According to one exemplary embodiment, the wave profile used in the exemplary corrugated member 210 may have a peak to peak wavelength 310 of between 0.25 and 1.5 inches, a material thickness 320 of between approximately 0.015 and 0.1 inches, and a wave height 330 of between about 0.13 and about 0.75 inches. According to one exemplary embodiment, the wave profile used in the exemplary corrugated member 210 may have a peak to peak wavelength 310 of about 0.5 inches, a material thickness 320 of approximately 0.031 inches, and a wave height 330 of approximately 0.25 inches. However, these parameters may be selectively varied to modify the resulting qualities of the corrugated member 210. Furthermore, according to one exemplary embodiment, the corrugated member properties assume an average wavelength to amplitude ratio (λ/H) of approximately 2:1. According to alternative embodiments, the exemplary wave profile 300 assumes an average wavelength to amplitude ratio (λ/H) ranging from approximately 1:1 to 3:1. According to other alternative embodiments, the exemplary wave profile 300 assumes an average wavelength to amplitude ratio (λ/H) ranging from approximately 0.5:1 to 4:1. Alternatively, the dimensions and parameters of the wave profile 300 may be further modified outside the ranges provided above to vary the pad properties according to varying needs and desired properties for various applications.

According to one exemplary embodiment, the use of a corrugated member 210 having the wave profile 300 illustrated in FIG. 9A provides numerous advantages to the resulting corrugated foam cell system 200. First, the use of the corrugated member 210 having a sinusoidal wave profile 300 increases the area over which an impact to the corrugated foam cell system 200 is dispersed for a defined length, relative to a system having a planar plate. Specifically, according to one exemplary embodiment illustrated in FIG. 9B, as the corrugated foam cell system 200 is impacted by a force (F), energy associated with that impact is translated through the foam to the corrugated member 210. As the energy from the force (F) reaches the varied surface of the corrugated member 210, the corrugated member 210 compresses vertically and expands (E) horizontally and energy is dispersed through the corrugation both perpendicular to the plane of the corrugation along multiple ridges, and parallel to the plane of the corrugation through the adjacent material.

According to one exemplary embodiment, the corrugated member 210 exhibits a nearly linear relationship between the applied force (F) and the deformation rates of the corrugated member for small deflections (approximately less than 35% of the original height and 20% of the original width). This linear relationship between the applied force (F) and the deformation rates allows for energy storage in the corrugated member 210 so that less of the impact force (F) is directly and immediately transferred to the body of the user as in the case of a flat plate.

FIG. 10 illustrates an assembled corrugated foam cell pad 400, according to one exemplary embodiment. As shown, the assembled corrugated foam cell pad 400 includes a foam upper 420 and a foam lower member 430 having a corrugated member 410 disposed there between. Furthermore, as illustrated, a nylon or other appropriate encasing 450 surrounds the foam cell pad to provide wear protection to the exemplary system. As illustrated, the assembled corrugated foam cell pad 400 eliminates the traditional hard outer shell typically associated with shoulder pads. The elimination of the hard outer shell reduces injuries to body parts such as fingers and hands that may be impacted between two non-compressible surfaces. Additionally with a thick nylon encasing, the corrugated foam cell pad 400 will have sufficient durability to last for a number of years. Furthermore, according to one exemplary embodiment, the materials used in the construction of the protective pads allow the pad system to be washable as the exemplary system consists of water resistant materials such as polyurethane foam, nylon, and Lexan.

In addition to dispersing energy imparted from an impact, the present exemplary pad plate system simultaneously provides selective support and mobility to the athlete incorporating the system. Specifically, according to one exemplary embodiment, the wave profile 300 of the plate provides a high level of stiffness in the direction parallel with the ridges, while providing flexibility in the direction transverse to the ridges of the sinusoidal plate. That is, the present exemplary configuration allows the plate to be bent and rotated about an axis that is perpendicular with the ridges. According to one exemplary embodiment, the direction and orientation of the ridges, and consequently the unidirectional flexure of the plate, can be selectively designed to allow for maximum mobility for football players without compromising safety. The direction, orientation, and shape of the ridges may be modified to maximize player flexibility and limb movement, thereby enhancing player safety and performance. According to one exemplary embodiment, the ridges may be designed and oriented to closely align with the natural movement of an athlete's body.

Additionally, the amplitude, wavelength, and thickness of the wave profile 300 of the corrugated member 210 can be varied to selectively introduce and design for areas of flexure. As illustrated in FIG. 9C, an area 350 of the wave profile 300 may have a reduced amplitude 330, wavelength 310, and/or thickness 320 to vary the bending properties of the resulting corrugated foam cell system 200.

The preceding description has been presented only to illustrate and describe embodiments of the presently disclosed protective pad systems and methods. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. Many modifications and variations are possible in light of the above teachings. 

1. A protective pad system, comprising; a vest comprising a back region, a left shoulder region, a right shoulder region, and a chest region; at least one left shoulder pad hinged relative to the left shoulder region of the vest; at least one left front motion restraint device positioned and configured to transfer impact force from the at least one left shoulder pad to the chest region of the vest; at least one right shoulder pad hinged relative to the right shoulder region of the vest; and at least one right front motion restraint device positioned and configured to transfer impact force from the at least one right shoulder pad to the chest region of the vest.
 2. The protective pad system of claim 1, further comprising: at least one left back motion restraint device positioned and configured to transfer impact force from the at least one left shoulder pad to the back region of the vest; and at least one right back motion restraint device positioned and configured to transfer impact force from the at least one right shoulder pad to the back region of the vest.
 3. The protective pad system of claim 2, wherein the at least one left front motion restraint device comprises a tether coupling a first side of the at least one left shoulder pad to the chest region of the vest; wherein the at least one right front motion restraint device comprises a tether coupling a first side of the at least one right shoulder pad to the chest region of the vest; wherein the at least one left back motion restraint device comprises a tether coupling a second side of the at least one left shoulder pad to the back region of the vest; and wherein the at least one right back motion restraint device comprises a tether coupling a second side of the at least one right shoulder pad to the back region of the vest.
 4. The protective pad system of claim 3, wherein each tether has an adjustable free length.
 5. The protective pad system of claim 4, wherein each tether comprises hook-and-loop fastener features.
 6. The protective pad system of claim 3, wherein each tether has a fixed free length.
 7. The protective pad system of claim 3, wherein each tether is relatively rigid.
 8. The protective pad system of claim 3, wherein each tether is somewhat elastic.
 9. The protective pad system of claim 3, wherein each tether comprises webbing.
 10. The protective pad system of claim 3, wherein each tether comprises a textile having a generally triangular shape.
 11. The protective pad system of claim 3, wherein each tether has a free length that is between about 30% and about 40% of the length of the radial distance from the respective tether to an axis of rotation of the respective shoulder pad relative to the vest.
 12. The protective pad system of claim 11, wherein each tether has a free length that is about 35% of the length of the radial distance from the respective tether to an axis of rotation of the respective shoulder pad relative to the vest.
 13. The protective pad system of claim 1, wherein the at least one left shoulder pad is hinged relative to the left shoulder region of the vest by a top tether having a first end attached near a top of the at least one left shoulder pad and a second end attached to the left shoulder region of the vest; and wherein the at least one right shoulder pad is hinged relative to the right shoulder region of the vest by a top tether having a first end attached near a top of the at least one right shoulder pad and a second end attached to the right shoulder region of the vest.
 14. The protective pad system of claim 13, wherein each top tether has an adjustable free length.
 15. A method of providing shoulder protection, the method comprising: providing a vest comprising a back region, a left shoulder region, a right shoulder region, and a chest region; providing at least one left shoulder pad hinged relative to the left shoulder region of the vest; providing at least one right shoulder pad hinged relative to the right shoulder region of the vest; transferring impact force from the at least one left shoulder pad to the chest region of the vest upon impact to the at least one left shoulder pad; and transferring impact force from the at least one right shoulder pad to the chest region of the vest upon impact to the at least one right shoulder pad.
 16. The method of claim 15, further comprising: transferring impact force from the at least one left shoulder pad to the back region of the vest upon impact to the at least one left shoulder pad; and transferring impact force from the at least one right shoulder pad to the back region of the vest upon impact to the at least one right shoulder pad.
 17. The method of claim 16, wherein transferring impact force from each of the at least one right shoulder pad and the at least one left shoulder pad to the chest and back regions of the vest comprises transferring impact force with a tether.
 18. The method of claim 17, further comprising adjusting a free length of each tether to provide a desired range of arm and shoulder motion.
 19. The method of claim 18, further comprising adjusting a free length of each tether to be about 35% of the distance between an axis of rotation of the respective shoulder pad relative to the vest.
 20. A protective pad system, comprising; a vest comprising a back region, a left shoulder region, a right shoulder region, and a chest region; at least one left shoulder pad hinged relative to the left shoulder region of the vest; a first tether coupling a first side of the at least one left shoulder pad to the chest region of the vest; a second tether coupling a second side of the at least one left shoulder pad to the back region of the vest; at least one right shoulder pad hinged relative to the right shoulder region of the vest; a third tether coupling a first side of the at least one right shoulder pad to the chest region of the vest; a fourth tether coupling a second side of the at least one right shoulder pad to the back region of the vest. 